KTM 250 sx shift lever hits chain

mx4all
Edited Date/Time 6/11/2019 10:26am
Hello.

Bought a 250 sx -18 recently and rode it for the first time today.
Had a hard time getting my foot under the shift lever so I raised it one step but then it would hit the chain when up shifting.
Had 14-50 gearing so I figured I would try 13-48 and see if that helps. But it didn't. Don't know if I should try a 12 sprocket or if there is a different lever? Never had these problems on 4 strokes..

These pics are of the 13 sprocket in two different positions.







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Superdave19
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Superdave19 6/8/2019 9:42am
6/8/2019 9:42am
- It's installed too high... Unbolt it, and reinstall a tooth lower.
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lostboy819 6/8/2019 9:56am
6/8/2019 9:56am Edited Date/Time 6/8/2019 9:58am
Yep, shifter is set way too high, if you can't shift with it in the correct position then your body and feet are not in the correct riding position. LOL that is the highest I have ever seen anyone set their shifter it should be close to level with the top of the foot peg and don't change your gearing by going to smaller sprockets because that wont fix your incorrect body position either. Pinch
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byke
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byke 6/8/2019 9:59am
6/8/2019 9:59am Edited Date/Time 6/8/2019 9:59am
Remember when we were supposed to aim our levers down to force our elbows up? Now everybody has them pointed straight out. Anyway, form doesn't matter unless you're trying to make a career out of riding. If you like the shifter mounted too high, then run it high. If it hits the chain, then make one with a different bend. Just follow the basic workflow of problem solving.
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lostboy819 6/8/2019 10:03am
6/8/2019 10:03am Edited Date/Time 6/8/2019 10:05am
And your counter shaft sprocket is not installed correctly, the washer is not centered on the shaft so it could be hanging up on the shaft shoulder or splines or it could be the wrong washer.
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BobPA
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BobPA 6/8/2019 10:43am
6/8/2019 10:43am
lostboy819 wrote:
And your counter shaft sprocket is not installed correctly, the washer is not centered on the shaft so it could be hanging up on the shaft...
And your counter shaft sprocket is not installed correctly, the washer is not centered on the shaft so it could be hanging up on the shaft shoulder or splines or it could be the wrong washer.
Something is way wrong with your countershaft sprocket...
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Texas Built
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Texas Built 6/8/2019 11:03am
6/8/2019 11:03am Edited Date/Time 6/8/2019 11:04am
lostboy819 wrote:
And your counter shaft sprocket is not installed correctly, the washer is not centered on the shaft so it could be hanging up on the shaft...
And your counter shaft sprocket is not installed correctly, the washer is not centered on the shaft so it could be hanging up on the shaft shoulder or splines or it could be the wrong washer.
The bolt is loose so the washer is sagging. You can see the line where it sat when it was installed. It's fine.
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mx4all 6/8/2019 11:04am
6/8/2019 11:04am
lostboy819 wrote:
And your counter shaft sprocket is not installed correctly, the washer is not centered on the shaft so it could be hanging up on the shaft...
And your counter shaft sprocket is not installed correctly, the washer is not centered on the shaft so it could be hanging up on the shaft shoulder or splines or it could be the wrong washer.
BobPA wrote:
Something is way wrong with your countershaft sprocket...
Wasn't tightened at the time of the pics, just tested the 13 sprocket.. I just changed the fotpegs to another brand that is a few mm lower and further from the levers so I hope that will do it.

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Killer Customz
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Killer Customz 6/8/2019 11:04am
6/8/2019 11:04am Edited Date/Time 6/8/2019 11:07am
These pictures are of a 2020 KTM 250SX. Stock sprocket is a 14T. I'd guess that your shift lever or shift shaft are bent. I do see what people are talking about with your washer, but assume that it's just not tightened down since you are swapping sprocket sizes.





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byke
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byke 6/8/2019 11:05am
6/8/2019 11:05am
It looks like he's working on the bike. You can see the parts on the stand, probably replacing the chain/sprockets and adjusting the shifter and noticed the interference.
lostboy819 6/8/2019 11:30am
6/8/2019 11:30am Edited Date/Time 6/8/2019 8:57pm
When I started wrenching at my first motorcycle shop in the 70s the best advice I ever got from a old mechanic is "never put something on finger tight" thinking you will tighten it later. Cool
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mx4all 6/8/2019 11:43am
6/8/2019 11:43am
If you check pic or 2 and 4 in the first post, you'll see one step changes the position pretty much. I would like a step in between them but that's not possible ofcourse. I'll try the footpegs and see if they do the magic
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Andy_Greenney 6/8/2019 12:30pm
6/8/2019 12:30pm
Keep it that high so you can shift it by hand
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Falcon
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Falcon 6/8/2019 12:36pm
6/8/2019 12:36pm
Andy_Greenney wrote:
Keep it that high so you can shift it by hand
I see what you did there.
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Andy_Greenney 6/8/2019 12:38pm
6/8/2019 12:38pm
Andy_Greenney wrote:
Keep it that high so you can shift it by hand
Falcon wrote:
I see what you did there.
It was a choice between that or “I’ve seen levers lower”....I stand by my choice.
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Deetsmx
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Deetsmx 6/8/2019 7:21pm
6/8/2019 7:21pm
I had a 17 husky 250 2 stroke and put the 350 shift left on there I believe. The tip is really close to the foot and moving it a little further away helped with getting a boot under it.
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Deetsmx
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Deetsmx 6/8/2019 7:22pm
6/8/2019 7:22pm
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Bruce372
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Bruce372 6/8/2019 7:45pm
6/8/2019 7:45pm
Where is jody with his hydraulic press when you need him?
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Robgvx
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Robgvx 6/8/2019 8:19pm
6/8/2019 8:19pm
I can’t ride with a low shifter. I often find on some bikes that one spline down is too low and one spline up is too high. Try an aftermarket shifter. Maybe the splines will be in a slightly different position.
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Mossy
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Mossy 6/8/2019 8:43pm
6/8/2019 8:43pm
Andy_Greenney wrote:
Keep it that high so you can shift it by hand
This made me blow a lot of air through my nose Silly
lostboy819 6/8/2019 9:00pm
6/8/2019 9:00pm
Andy_Greenney wrote:
Keep it that high so you can shift it by hand
Dungey already did all the testing so its good to go. Cool
2
Boomslang 6/8/2019 9:37pm
6/8/2019 9:37pm
lostboy819 wrote:
And your counter shaft sprocket is not installed correctly, the washer is not centered on the shaft so it could be hanging up on the shaft...
And your counter shaft sprocket is not installed correctly, the washer is not centered on the shaft so it could be hanging up on the shaft shoulder or splines or it could be the wrong washer.
The washer is the wrong way around.
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mx4all 6/9/2019 3:13am
6/9/2019 3:13am
lostboy819 wrote:
And your counter shaft sprocket is not installed correctly, the washer is not centered on the shaft so it could be hanging up on the shaft...
And your counter shaft sprocket is not installed correctly, the washer is not centered on the shaft so it could be hanging up on the shaft shoulder or splines or it could be the wrong washer.
Boomslang wrote:
The washer is the wrong way around.
Nope
fullfloater 6/9/2019 6:12am
6/9/2019 6:12am
lostboy819 wrote:
When I started wrenching at my first motorcycle shop in the 70s the best advice I ever got from a old mechanic is "never put something...
When I started wrenching at my first motorcycle shop in the 70s the best advice I ever got from a old mechanic is "never put something on finger tight" thinking you will tighten it later. Cool
Oh come on, nobody forgets.


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cmotodad
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cmotodad 6/9/2019 6:22am
6/9/2019 6:22am
In the past, Jody of MXA, suggested you put the shifter in a press and put more arc in the lever. this allowed a higher shifter without changing on the spines.
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Bennett59
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Bennett59 6/9/2019 6:39am
6/9/2019 6:39am
mx4all wrote:
If you check pic or 2 and 4 in the first post, you'll see one step changes the position pretty much. I would like a step...
If you check pic or 2 and 4 in the first post, you'll see one step changes the position pretty much. I would like a step in between them but that's not possible ofcourse. I'll try the footpegs and see if they do the magic
If your having a hard time getting under the shifter you could also instead of raising it go with a hammer head shifter and they have different lengths
1
mx4all 6/9/2019 7:10am
6/9/2019 7:10am
cmotodad wrote:
In the past, Jody of MXA, suggested you put the shifter in a press and put more arc in the lever. this allowed a higher shifter...
In the past, Jody of MXA, suggested you put the shifter in a press and put more arc in the lever. this allowed a higher shifter without changing on the spines.
I got a hydraulic press.. but doesnt the lever get weaker if you bends it in the press? Should you heat up the lever before pressing?
cmotodad
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cmotodad 6/9/2019 8:34am
6/9/2019 8:34am
A slight amount of heat will do a little but being aluminum, not like steel, it will bend a some amount without weakening. Propane from a bottle will do. I think a little more bend will give a slightly stronger shape.
YZed250
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YZed250 6/11/2019 10:26am
6/11/2019 10:26am
lostboy819 wrote:
And your counter shaft sprocket is not installed correctly, the washer is not centered on the shaft so it could be hanging up on the shaft...
And your counter shaft sprocket is not installed correctly, the washer is not centered on the shaft so it could be hanging up on the shaft shoulder or splines or it could be the wrong washer.
BobPA wrote:
Something is way wrong with your countershaft sprocket...
mx4all wrote:
Wasn't tightened at the time of the pics, just tested the 13 sprocket.. I just changed the fotpegs to another brand that is a few mm...
Wasn't tightened at the time of the pics, just tested the 13 sprocket.. I just changed the fotpegs to another brand that is a few mm lower and further from the levers so I hope that will do it.

How did you like the new pegs? How tall are you and do you ride in a lot of soft tracks with ruts? They look like Pro Circuit steel or DRC steel pegs.
Texas Built
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Texas Built 6/11/2019 11:52am
6/11/2019 11:52am
Saw this yesterday.



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